DFM Optimization for Automotive Engine Mount Bracket Manufacturing
Summary
Ford Motor Company's Dearborn Engine Plant reduced manufacturing costs by 32% and improved production efficiency by 28% through comprehensive DFM optimization of their V8 engine mount bracket assembly. The project eliminated secondary operations and standardized fastening methods across three vehicle platforms.
The Challenge
Initial Need:
Ford's Dearborn Engine Plant faced escalating production costs and quality issues with their steel engine mount bracket used across F-150, Mustang GT, and Explorer platforms. The original design required 14 separate manufacturing operations including multiple secondary machining steps, precision drilling of 12 mounting holes with ±0.05mm tolerances, and post-weld heat treatment to meet ASTM A36 structural requirements.
Pain Points:
Excessive tooling costs: $2.3M annually across 14 different forming dies and fixtures
Secondary machining requirements: 67% of parts required post-forming drilling operations, adding 8.5 minutes per unit
Quality defects: 4.2% scrap rate due to hole location tolerance violations exceeding ±0.1mm specification
Material waste: 23% material utilization efficiency with significant trim scrap in stamping operations
Our Solution
Our Approach:
The DFM optimization initiative focused on consolidating manufacturing operations through integrated design changes that eliminated secondary processes while maintaining structural integrity and crash performance requirements. The engineering team conducted comprehensive failure mode analysis using ISO 26262 functional safety standards and implemented design modifications that leveraged existing stamping press capabilities.
Methodology:
Engineers utilized advanced finite element analysis (FEA) software including ANSYS Mechanical and LS-DYNA crash simulation to validate design modifications against Ford's internal DVP&R requirements. Material selection shifted from ASTM A36 hot-rolled steel to high-strength low-alloy (HSLA) 350 grade steel, enabling thinner gauge while maintaining equivalent load-bearing capacity.
Final Summary:
The optimized design eliminated 9 of 14 manufacturing operations through integrated pierce-and-form stamping operations, reduced fastener variety from 6 to 2 standard M10 grade 8.8 bolts, and achieved 89% material utilization efficiency. Production cycle time decreased from 23.5 minutes to 14.2 minutes per unit while maintaining all original performance specifications.
Execution
Process Description:
Implementation began with comprehensive supplier capability assessment, identifying Magna International's stamping facility in Windsor, Ontario as the optimal manufacturing partner. Progressive die design incorporated advanced sensor technology for real-time quality monitoring, enabling statistical process control with Cpk values exceeding 1.67 for all critical dimensions.
Outcome
Value Comparison:
The DFM optimization delivered exceptional financial and operational results, with total manufacturing cost reduction of $4.7M annually across the three-platform production volume. Direct labor savings reached $1.8M through elimination of secondary operations, while material cost optimization contributed an additional $1.2M in annual savings.
Client Testimonial:
"The comprehensive DFM approach transformed our engine mount bracket manufacturing from a multi-step, high-cost operation into a streamlined, single-operation success story. We not only achieved our 30% cost reduction target but exceeded it while improving quality metrics across all platforms."
- Sarah Martinez, Manufacturing Engineering Manager, Ford Motor Company Dearborn Engine Plant